Role of R&D From Early Development to Commercialization

by R.A. Speranzini

AECL2010 February 2

•CANDU and AECL•R&D and D&I•Evolution: ACR, Fuel •Innovation: SCWR•New Products & Services•Plans, Processes & QA

Quebec, CanadaGentilly 2 1 unit

RomaniaCernavoda 2 units

Ontario, CanadaDarlington 4 unitsPickering 6 unitsBruce 8 units

New Brunswick, CanadaPoint Lepreau 1 unitArgentinaEmbalse 1 unit

Republic of KoreaWolsong 4 units

India13 units, 5 units under construction, 2 in pre-project phasePakistanKANUPP 1 unit

ChinaQinshan 2 units

Point Lepreau, Canada Pickering, Canada Qinshan, China

Heavy Water Reactors based on the CANDU designin operation, under construction, or under refurbishment

- located on four continents

AECL

AECL Commercial BusinessNew Products & Services DevelopmentDelivery of AECL Projects and Commercial Products &

Services

Nuclear Platform R&DEnsure the Health & Safety, Licensing and Design Basis for Canadian nuclear technology-COG R&D program & support for operating stationsSupport Public Policy and regulation for nuclear technologyDevelop advanced, pre-commercial, CANDU technologyMaintain capability and expertise

Decommissioning & Waste Management(Legacy Management)Nuclear R&D Facilities

Nuclear Platform

}LeveragedBusiness

AECL has dual role

• Advanced CANDU Reactor (ACR™) Development

AECL’s Range of R&D ActivitiesResearch Reactors

Products &Services

Res

earc

h Dev

elop

men

t

Engi

neer

ing

Future GenerationGen IV

EnhancedCANDU-6

ACR®

Proj

ects

U nderlying Science

Fuel/FuelCycles

FuelChannels

Heavy WaterTechnology

Components& Systems

SafetyTechnology

Rad. Sciences/Env. Tech.

Control &InformationTechnology

Underlying Science

Deuterium(mg/dm2)

0.25

0.20

0.15

0.10

Effect of Fe and C on D Ingress

SMART CANDU™An integrated package of hardware and software tools, sensors and work processes that facilitate on-line monitoring, analysis, diagnostics and control of processes and equipment to optimize safety and performance and maximize plant life.

GATHER

ACT

AECL EACL

OpticalPressure Sensor

OpticalConnector

Benefits• Improved safety, performance and capacity factors• Optimized OM&A• Enhanced staff performance and response time• Integrated plant life management

ThermAND™

ChemAND® IPTDIM

ANALYZE

DISPLAY

DISTRIBUTE

Proven Technology:Moving from ideas to concepts to markets

• How is technology developed and implemented?• How do you know if it is “proven” or “mature”?• Can you measure or evaluate maturity?

Need a structured approach:• R&D• Design and Integration (D&I)• Management Systems

o Objectiveso Planningo Processeso Quality System (QA)

R&D Planning process (Procedure CW 00-621.1)

Begin with Strategic Plans (Corporate and R&D)•R&D Workshop held annually (Sept-Nov); develop basis for Strategic Plan (define Strategic Objectives, R&D Priorities)

Working Groups (membership from all AECL business units)•Input from customers & stakeholders (define R&D requirements)•Prepare Technology Development Plans (Objectives, Goals;prepare/review proposals with deliverables)•Recommend programs to achieve objectives (outcomes)

R&D Review Committee meeting – March•Ensure consistency with strategic directions•Ensure priority R&D needs are being met (identify gaps)•Approve proposed R&D programs, or modify

Strategic Objectives, and R&D Planning and Prioritization

Strategic Objectives – Nationaltied to socio- & economic factors

• Maximize the utilization of resources (U, Th)• Security of supply• Localization of technology• Minimize waste (reduce repository space and

performance requirements while managing costs)

• Reactor synergies (maximize integration of HWR with LWR and FBR fuel cycles; e.g. RU, actinide burning, etc)

• Sustainability

Strategic Objectives – Safety, Operations

• Maintain safety, design and licensing basis• Equipment reliability and plant performance• Life Cycle Management, Plant Life Extension• Manage component aging (SGs, F/Cs)• Material degradation assessment & mitigation• Dose reduction and source-term reduction• Environmental performance(reduce emissions)• Improve outage performance (faster/better

inspections, maintenance strategies)• Capability, Knowledge Management

Inno

vatio

n

Years from today20 30 40 50 60

3-35 years

70

25-60 years

AdvancedCANDU Reactor

CANDU SCWR

CANDU X50 - 85 years

CurrentGeneration CANDU

Continually enhance both the design and applications, each generation is built firmly on the previous generation

Reactor Development:CANDU Evolution

Gen IV

Gen V

Gen III+

Design and Integration Process• Defining and refining technology choices

• Defining Schedule, Critical Path and Milestones

• Enable optimal use of R&D results

• Defining design stages

• Integration of development strategies

• Moving from: ideas to concepts to markets

Typical Design Stages

Stages Definition Contact with Regulators Comment

1. Pre-conceptual Options and ideas Global Principle Is the concept licensable?

Between stages 1 and 2

2. Conceptual Design & Fuels Requirements Document

3. Preliminary Safety Analysis Design Review & iteration

4. Basic Design

Specifications and Standards;

Systems Optimizations;First quote

Formal license discussions Vendor

5. Detailed Design Testing and Margins;Procurement

Licensing and Design Reviews Vendor

6. Final DesignConstruction,

Schedule & Costing

User

Process is iterative: R&D and D&I

Design and Integration

R&D Projects• Physics• Fuel and Fuel Cycles• Materials• Chemistry • Thermalhydraulics• Safety • Component Design

& BOP

Technical & PerformanceRequirements

Technical & Performance

Results

CANDU 6 Darlington ACR - 1000

Advanced CANDU Reactor - ACRCANDU 6, Darlington, ACR Reactor Core Comparison

• Calandria 7.6m (similar to CANDU 6)

• Lattice 26 x 26• Heavy water hold-up

reduced

CANDU 6 Darlington ACR-1000Number of Channels 380 480 520

7.6 8.5 7.6286 286 240265 312 235192 280 0466 602 240

Reactor Core DiameterLattice Pitch

Volume of D20 in HTS (m )Total Volume D20 (m )

Volume of D20 in Moderator (m )

•Evolutionary approach adopted by building on CANDU 6 design, project and operational experience

•Retained traditional CANDU featuresoModular horizontal fuel channelsoSimple, economical fuel bundle designoHeavy water moderatoroOn-power fuelingoHigh neutron economy

•Feedback from CANDU plantsoOperating CANDU plantsoConstruction and commissioning feedback from QinshanCANDU 6 project

Basis of ACR Design

• Improve core characteristics and reduce D2O inventoryoH2O coolant in D2O moderated latticeoSmaller lattice pitchoSlightly enriched uranium fuel

•Reduce fuel element rating and increase maximum channel and bundle powers

oUse CANFLEX fuel bundle design

•Increase operating margin and turbine efficiencyoThicker pressure tubeoHigher reactor coolant and secondary steam temperature and pressure

•Reduce size of reactor core and reactor building

ACR Innovations

Fuel Development

NPD7-element

220 kW

Douglas Point19-element

420 kW

Pickering28-element

640 kW

Bruce37-element800-900 kW

CANFLEX43-element

1200 kW

•Lower temperatures•Improved heat transfer•Higher burnups•Improved core characteristics

Evolution of CANDU Fuel

•Simple, inexpensive, with excellent performance•Easy to manufacture & localize•Reactors optimized to use natural uranium fuel:

•very high “neutron economy”•on-power refuelling, heavy water coolant and moderator

Qinshan 37-element CANFLEX 43-element

Design Qualification Process

Fuel Design& Analysis

MaterialProperties

Bundle & channel

power, fuel burnup,

physics code qualification

Acceptable Performance

Fuel DesignRequirements,

DVP & Design Documentation

Bundle Mechanical

Performance Critical Heat Flux, Pressure Drop,

Post-dryout

Fuel & Bundle Performance

ReactorPhysics

Thermal-hydraulics

Thermal properties, oxidation

Out-ReactorTesting

Design Review, CNSC Approval

DemonstrationIrradiation

SustainableFuel input Hydrogen and process heat

plus heavy water

Drinking water

Gen IV International Forum - GIFInnovation: SCWR CANDU

Industrial isotopes

Brine

T1,P1

T2,P2

T3,P3

Electric power

Pre-Conceptual Design Stage Options and Ideas

more iterations of R&D and D&I, more time• SCWR is the logical development for water reactors• Build on existing knowledge - smooth development path•Can apply available tools, models and codes•New design concepts• No turbine development required - compact footprint• High cycle efficiency (> 49%) - lower cost•Materials and cycles known from fossil plants - low corrosion• Viable in large size range (300 to 1400 MW(e)) - modular build•Direct steam-cycle option eliminates expensive HX systems•Reheat cycle raises overall efficiency ( 48-55%)•Totally passive safety argument potential

SCWR R&D MenuNeed to focus on critical path technology and facility items

Fuels and MaterialsWater Chemistry Cladding and material screening Fuel bundle design studies SCW radiolysis SCW heat transfer tests, fluid flow and analysis Corrosion Fuel selection and thorium cycles Reactor Systems and BOPCore neutronics and TH design studiesHigh temperature and pressure structures for reactor systems Analytical and experimental evaluations of passive cooling systems Reactor system feasibility Process heat and co-generation

Safety and Design EvaluationPre-conceptual design studies Neutronics and TH evaluations Stability analysis and experimentsSafety analysis and depressurization Safety systems evaluation Safety analysis and inherent safety Fast reactor core design Experimental evaluation of physics parameters Fuelling options Plant layout (related to Economics crosscut) Scaling rules In-pile loopFuel Cycle CrosscutCrosscutting efforts Resource utilization, synergisms with fast reactors

GIF SIAP: Areas for Consideration

• Overarching Project Plan

• Requirements and Specificationso User requirementso Assess viabilityo Engage regulatory agencies; early and on-going

• Evolution from Concept to Producto Manage risks

• Staged Approach and Decision-Making

GIF SIAP: from Concept to Product

• Product Focuso Economicso Manage Risk

LicensingConstructionOperationWaste Management / Decommissioning

• Concepts are at different stageso Keep “product focus” requirements in mind at all

stageso “Concept to product gaps”

GIF SIAP: Staged Approach• Consider use of a staged approach to identify

progress of each design concept• Four Stages

FeasibilityExperimentalDemonstrationCommercialization

• Develop scheme to place each concept in correct stage

• Develop scheme for collaboration of researchers with government, utilities, industry and institutes at each stage (important at experimental stage)

• Provides basis to develop the overarching project plan

Process to Decrease Time to Market (Procedure CW 00-621.5)

•Identify customer need – customer pull or technology push?•Identify product and prepare conceptual business case•Product Development Plan

oDevelopment phases 1, 2, 3, etcoIdentifies Quality Requirements for project and productoAssessment of technical and commercial riskoStaged risk reduction

•Product Design and confirm product requirements are satisfied•Hand over for commercial application

AECL Products:•Fuel channel inspection (AFCIS)•Steam generator inspection (X-probe)•ECC strainers•Pump seals•Passive autocatalytic recombiners for H2 mitigation

New Products and Services: The Stage-Gate Process

NDE and Gauging Heads

AECL staff design probes and mechanical heads for fuel channel inspection

X-probe for tight radius SG U-bendsField Examples of Degraded Broach Plates

H07 Support with Loss of Ligaments and Partially Degraded Land

Regions H07 Support with Severely Degraded Land Regions and Loss

of Ligaments

ECC Strainers• Worked closely with regulators and

utilities to define the problem, develop solutions, and supply replacement strainers

• Shown is Point Lepreau strainer pre-assembled at CRL

Pump Seals

• Developed CANDU PHT pump seals used at PLGS in 1970’s

• Developed upgraded PHT pump seals in 1990’s– Supplied to Bruce,

Darlington & US (Darlington seal fits directly into PLGS.)

PAR – for Hydrogen Mitigation• AECL’s proprietary

wetproofed catalyst performs in challenging conditions (ambient temperature, 100% relative humidity)

• Sold to Finland and France for hydrogen mitigation in PWR containments

• Collaborated with Hitachi for ABWR applications

“Winning at New Products” by R.G. Cooper; provides a systematic framework for the stages of review, evaluation and decision making in taking a “product” from the “idea” stage to the “market launch” stage while managing risk

Gate 1 Initial screenStage 1 Preliminary investigationGate 2 Second screenStage 2 Detailed investigationGate 3 Decision on the Business CaseStage 3 DevelopmentGate 4 Post Development ReviewStage 4 Testing and ValidationGate 5 Pre-commercialization Business AnalysisStage 5 Full Production and Market Launch

After 6 – 18 months the project team is disbanded and the product becomes a “regular” product

New Products and Services: The Stage-Gate Process

SummaryMoving from ideas to concepts to markets• It is possible to:

– advance nuclear technology; and,– successfully develop and commercialize technologies

• Need a structured approach:– R&D (from idea generation, to field implementation)– Design and Integration (D&I)– Management Systems

ObjectivesPlanningProcessesQuality System (QA)

Nuclear Technology R&D is an investment that generates economic, social and environmental returns.